Variable Valve Timing Actuator Removal/Installation

1. Insert a suitable bolt (M6 X 1.0, length 25-35 mm {0.99-1.3 in}) into the engine front cover upper blind plug and tighten it until it contacts the chain tensioner arm, and then rotate it back one turn. (Set the bolt slightly away from the chain tensioner arm so that it does not contact it.)
   Fig 4: Identifying Chain Tensioner Arm Bolt

   Courtesy of MAZDA MOTORS CORP.
2. Drain the engine oil in the chain tensioner.
   • The plunger of the chain tensioner will be pushed in by rotating the exhaust camshaft. As a result, engine oil leakage will occur.
   1. Set a wrench on the cast hexagon of the exhaust camshaft and one on the cast hexagon of the intake camshaft.
   2. While holding the intake camshaft so that it does not rotate, move the wrench on the exhaust camshaft side back and forth. (Repeat approx. 10 times)
   Fig 5: Rotating Exhaust Camshaft
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3. Remove the wrench set to the intake camshaft.
4. Using the SST (48 G010 4A0), release the chain tensioner ratchet lock.
   Fig 6: Identifying Tensioner Release Service Tool 49 G010 4A0 Component Parts

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   1. Seat the nut to the cast hexagon stud and tighten by hand. At this time, leave the handle lever removed.
   Fig 7: Identifying Tensioner Release Stud & Nut
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   2. Set the stud in the engine front cover lower service hole. (Tighten by hand until the hexagon contacts the engine front cover).
   Fig 8: Identifying Tensioner Release Stud & Service Hole
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   3. Rotate the stud counterclockwise and align it with the tensioner release arm insertion hole to the 2 o'clock position.
   Fig 9: Tensioner Release Stud At 2:00 O'clock Position
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   4. Insert the tensioner release arm into the tensioner release arm insertion hole of the stud. (Insert until seated to the nut).
   Fig 10: Inserting Tensioner Release Arm
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   5. Assemble the handle lever to the stud.
   Fig 11: Inserting Tensioner Release Handle
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   6. Assemble the 49 G010 403 (Tensioner release guide) and flange bolt together and set it to the installation area of the idler pulley. (Tighten flange bolt by hand)
   Fig 12: Identifying Tensioner Release Guide
   Courtesy of MAZDA MOTORS CORP.
   7. Rotate counterclockwise slowly until the handle lever contacts the tensioner release guide. The ratchet lock will release by rotating to the position which contacts the tensioner release guide.
      Fig 13: Rotating Tensioner Release Handle Lever

      Courtesy of MAZDA MOTORS CORP.
      • If the tensioner release arm cannot be deformed and removed by hand, turn the nut and then remove it.
   Fig 14: Removing Tensioner Release Arm
   Courtesy of MAZDA MOTORS CORP.
5. Verify that the ratchet lock is correctly released using the following procedure.
   1. Hold the handle lever using the left hand.
   2. With the right hand, move the wrench set to the exhaust camshaft back and forth. At this time, if the handle lever does not thrust back in conjunction with the movement of the wrench, the ratchet lock is released.
      • If the handle lever thrusts back in line with the movement of the wrench, the ratchet lock is not released. If this occurs, release the lock using the following procedure.
      NOTE:

      • Continue to perform the following procedure until the handle lever does not thrust back. If it does not unlock, further rotate the handle lever as the chain tensioner position has deviated.
      • Lock is not released  While slowly rotating the handle lever counterclockwise, (while pressing tensioner release guide ahead), move the wrench set to the exhaust camshaft back and forth.
      Fig 15: Rotating Handle Lever Counterclockwise
      Courtesy of MAZDA MOTORS CORP.
6. While applying pressure to exhaust camshaft with the right hand in the clockwise direction, crimp the bolt set in the procedure (1) approx. 5 mm using the left hand. Fix the tensioner arm. See Fig 4.

1. Place alignment marks on the camshaft and variable valve timing actuator as shown in the figure so that the variable valve timing actuator is re-assembled in its original position.
Fig 19: Identifying Alignment Marks On Camshaft And Variable Valve Timing Actuator
Courtesy of MAZDA MOTORS CORP.
2. Fix the camshaft in a vise.
Fig 20: Fixing Camshaft In Vise
Courtesy of MAZDA MOTORS CORP.
3. Loosen the variable valve timing actuator installation bolt.

1. Fix the camshaft in a vise.
2. Align the marks on the camshaft and the variable valve timing actuator.
3. Tighten the variable valve timing actuator installation bolt.

Tightening torque 

69-75 N.m {7.1-7.6 kgf.m, 50.9-55.3 ft.lbf} 

Adhesive agent thickness 

1.0 mm {0.039 in} 

Fig 24: Identifying Adhesive Agent Applying Area

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Tightening procedure 

1. 5.0-9.0 N.m {51.0-91.7 kgf.cm, 444.3-79.6 in.lbf} 
2. 14.0-17.0 N.m {1.5-1.7 kgf.m, 10.4-12.5 ft.lbf} 

Fig 25: Identifying Camshaft Caps Bolts Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Tightening torque 

69-75 N.m {7.1-7.6 kgf.m, 51-55 ft.lbf} 

• If not aligned, loosen the camshaft sprocket bolt and repeat the procedure from Step 36.

Tightening torque 

8.0-11.5 N.m {81.6-117.2 kgf.cm, 70.9-101.7 in.lbf} 

Fig 28: Identifying Silicone Sealant Applying Area And Engine Front Cover Upper Blind Plug

Courtesy of MAZDA MOTORS CORP.

Tightening torque 

18-22 N.m {1.9-2.2 kgf.m, 13.3-16.2 ft.lbf} 

Fig 29: Identifying Cylinder Block Lower Blind Plug

Courtesy of MAZDA MOTORS CORP.

Tightening torque 

10.0-14.0 N.m {102.0-142.7 kgf.cm, 73.8-103.2 in.lbf} 

Fig 30: Identifying Engine Front Cover Lower Blind Plug

Courtesy of MAZDA MOTORS CORP.